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Old 08-31-2020, 07:00 PM   #1
gasouthern1
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Default Cushman Hauler Pro Headlights wont work

I got a 2017 72v hauler pro today, the headlights worked yesterday but won’t work today. The fuses on the driver side next to batteries are good, I removed the switch and used a jumper to test and that didn’t work either, the bulbs look fine when removed. Are there any other fuses or relays that I should check? I know I’m missing something simple but I can’t figure it out for the life of me.
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Old 09-02-2020, 08:44 PM   #2
gasouthern1
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Default Re: Cushman Hauler Pro Headlights wont work

Does anyone know if the horn and the lights share a ground? Both switches have power, both the light and the horn are hooked up and neither work. The schematic on the Textron site is extremely hard to follow.
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Old 01-22-2022, 07:26 AM   #3
warriorpoet78
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Default Re: Cushman Hauler Pro Headlights wont work

gasouthern1: did you ever get this fixed? I have the exact same problem and just came across this post. TIA
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Old 08-12-2022, 10:11 AM   #4
nesnahjm
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Default Re: Cushman Hauler Pro Headlights wont work

The Hauler pro has a 72 volt to 13 volt DC to DC converter mounted on the left/driver side bolted to the floor panel under the seat below the tow switch. It is what supplies power for lights, horn and other 12v accessories. It has heavy red and a black wire going in on one side and yellow white and blue wires on the other side. It can short out and you will still be able to drive but none of the lights or horn will work. There is a 10 amp fuse mounted under the cover of the controller. It is the one closest to the front of the vehicle. Try the fuse first and if it arcs and blows then it is most likely the converter. Don't buy it from Amazon as you can find then way cheaper on other sites.
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Old 06-28-2023, 11:41 AM   #5
rdwrdw44
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Default Re: Cushman Hauler Pro Headlights wont work

Sorry, Newbie here. Where is the controller?
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Old 06-28-2023, 10:42 PM   #6
TheCartBoy
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Default Re: Cushman Hauler Pro Headlights wont work

Under the front seat, typically passenger side.
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Old 06-29-2023, 12:49 AM   #7
konakid
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Default Re: Cushman Hauler Pro Headlights wont work

I found this extremely helpful after posting a similar question earlier today. Same problem on about same vintage 72 volt Cushman Hauler Pro. No lights and no horn. And didn't know what this was - see pic attached.

Will check for fuse in controller enclosure - my controller is under cargo bed driver side at rear of vehicle. Converter is warm with key on, so assuming it has power and fuse must be good. So hoping that the converter is just bad.

I have 12v DC power to key switch - on 'first two terminals but no power to third and fourth (blue wires) terminals - see second pic attached. Assuming that suggests bad converter - correct???

Looks like special plugs/connectors - any suggestions on where to get identical part? Can't find any numbers on it before taking out. I have a feeling cart might not run or charge if disconnected since it appears connected to on-board charger.
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Old 06-29-2023, 01:05 AM   #8
konakid
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Default Re: Cushman Hauler Pro Headlights wont work

Follow up from post above. Found this part for $200+ (see attachment) - looks identical.

Before ordering - does anyone know if I can check the old one first? Which outputs should I confirm if working. Apparently it says "One switched output, one un-switched output, with ignition key input"

But not sure how to check.

To repeat from previous thread - I have 12v DC power to first two terminals (yellow and white) (see pic) on key switch and cart runs fine. But no power to second two terminals for lights (both blue wires).

So - where should I check for power out of converter - from blue and white?
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Old 06-29-2023, 04:05 AM   #9
Cartmaster
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Default Re: Cushman Hauler Pro Headlights wont work

http://www.nivelparts.com/cms/files/..._Converter.pdf

This might help. Full instructions including wiring diagram power out is red and black, power in is blue and yellow, white is the trigger wire.

Your two blue white wires on ignition switch will likely be one power in with 12 volts on it all the time probably fed from the voltage reducer via a fuse and the other should be 12 volts out to the lights when key is in second "on" position.
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Old 06-29-2023, 12:39 PM   #10
rdwrdw44
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Default Re: Cushman Hauler Pro Headlights wont work

Ok, found the controller and a site glass with "fuse" printed on the housing. Is there a way to check this fuse?IMG_6437.jpg
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